Ip Powerdsp g2 Man Rev2

IONPURE ®  G2 DISPLAY BOARD For use with G2 Power Controllers

Operation & Maintenance Manual

IP-POWERDSP-G2MAN June 2014 Revision 2

Manual Covers Part #: 10 Technology Drive Lowell, Massachusetts 01851 Tel: (866) 876-3340 Fax: 978-934-9499 978-934-949 9 www.ionpure.com

IP-POWERDSP-G2

IONPURE  ® 

G2 DISPLAY BOARD  – IP-POWERDSP-G2 IP-POWERDSP-G2 Table of Contents

DISCLAIMER DISCLAIMER STATEMENT STATEMENT .................................................................................................................. 4 PROPRIETARY PROPRIETARY RIGHTS STATEMENT STATEMENT ................................................................................................ 4 MANUAL MANUAL REVISION HISTORY............................................................................................................. 4 1

INTRODUCTION INTRODUCTION ............................................................................................................................. 5 1.1 Caution and Warning W arning Messages ................................................................................................ 5 1.2 General Description ................................................................................................................... 5

2

INSTALLAT INSTALLATION ION ............................................................................................................................... 7 2.1 Requirements............................................................................................................................. 7 2.2 Panel Mount ............................................................................................................................... 8 2.3 Connections Connections ............................................................................................................................... 8 2.3.1 Connections Connections to a Single G2 Power Controller....................................................................... 8 2.3.2 Connections Connections to Multiple G2 Power Controllers ..................................................................... 9 2.4 Power Controller Setup ............................................................................................................ 10 2.4.1 DC Output Current Range Selection .................................................................................. 10 2.4.2 Unit ID Selection................................................................................................................. 11

3

OPERATION OPERATION.................................................................................................................................. 12 3.1 Control/Navigation Control/Navigation Keys ........................................................................................................... 12 3.2 Menu Structure......................................................................................................................... 13

4

GETTING STARTED STARTED ..................................................................................................................... 23 4.1 Initial Startup ............................................................................................................................ 23 4.2 Output Current Adjustment ...................................................................................................... 23

5

TROUBLESHOOTING TROUBLESHOOTING................................................................................................................... 24

APPENDIX  – UL AND CE COMPLIANCE COMPLIANCE........................................................................................... 25

List of Figures Figure 1: G2 Display Board.................................................................................................................... 5 Figure 2: G2 Display Dimensions........................................................................................................... 7 Figure 3: Panel Cutout Dimensions ....................................................................................................... 8 Figure 4: Connections Connections to a Single G2 Power Controller ......................................................................... 9 Figure 5: Connections Connections to Multiple G2 Power Controllers ...................................................................... 10 IP-POWERDSP-G2MAN IP-POWERDSP-G2MA N Rev 2

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Figure 6: Current Range Selection DIP Switch .................................................................................... 10 Figure 7: Control/Navigation Keys ....................................................................................................... 12 Figure 8: Menu Tree Structure............................................................................................................. 13 Figure 9: OVERVIEW Screen Example ............................................................................................... 14 Figure 10: RUN Screen – Page 1 ........................................................................................................ 14 Figure 11: RUN Screen – Page 2 ........................................................................................................ 15 Figure 12: RUN Screen – Page 3 ........................................................................................................ 15 Figure 13: RUN Screen – Page 4 ........................................................................................................ 16 Figure 14: RUN Screen – Page 5 ........................................................................................................ 16 Figure 15: SETUP Screen – Page 1 .................................................................................................... 17 Figure 16: SETUP Screen – Page 2 .................................................................................................... 18 Figure 17: ALARMS Screen – Page 1 ................................................................................................. 18 Figure 18: ALARMS Screen – Page 2 ................................................................................................. 19 Figure 19: LOGS Screen ..................................................................................................................... 20 Figure 20: MAX VALUES Screen......................................................................................................... 20 Figure 21: MIN VALUES Screen .......................................................................................................... 21 Figure 22: MODULE OHMS&S Screen ........................................................................................ 22 Figure 23: DIAGNOSTICS Screen ....................................................................................................... 22

List of Tables

Table 1: Unit ID Selection .................................................................................................................... 11 Table 2: Troubleshooting ..................................................................................................................... 24

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Disclaimer Statement The operation and maintenance manual should provide complete and accurate information to meet your operating and/or service requirements based on the information available at the time of publication. The information in this manual may not cover all operating details or variations or provide for all conditions in connection with installation, operation and maintenance. Should questions arise which are not answered specifically in this manual, contact your equipment supplier. Siemens reserves the right to make engineering refinements that may not be r eflected in this manual. The material in this manual is for informational purposes and is subject to change without notice.

Proprietary Rights Statement This manual discloses information in which Siemens has proprietary rights. Neither receipt nor possession of this manual confers or transfers any right to the client, and by its retention hereof, the client acknowledges that it will not reproduce or cause to be reproduced, in whole or in part, any such information except by written permission from SIEMENS. The client shall have the right to use and disclose to its employees the information contained herein for the purpose of operating and maintaining the SIEMENS equipment, and for no other purpose. In the event the content of this manual is altered or section/items are omitted during reproduction, in whole or in part, and instructions or definitions within the reproduction result in personal injury to those who follow the altered instructions, the burden of responsibility for personal injury falls solely on the party who effects the reproduction.

Manual Revision History Event

Date

Description

Original Publication Rev 0

September 2011

Original publication

Rev 1

November 2011

Updated remarks on firmware in sections 3.2 and 5 Updated Figure 23

Rev 2

June 2014

Table 2

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1 Introduction 1.1

Caution and Warning Messages

WARNING and CAUTION labels are used to attract attention to essential or critical information in this manual. The labels are located to the left of the associated messages. Caution and Warning messages will be located immediately before related text. Warnings indicate condition, practices, or procedures that must be observed to avoid personal injury or fatalities.

Cautions indicate a situation that may cause damage or destruction of equipment or may pose a long-term healt h hazard.

Notes are also used to draw attention to information. Notes may be located before or after the related text. NOTE:

1.2

Notes are used to add information, state exceptions, and point out areas that may be of greater interest or importance.

General Description

Figure 1: G2 Display Board

The Ionpure® G2 Display Board IP-POW ERDSP-G2 is a digital controller designed specifically to function as the human interface that allows an operator to control and monitor the Ionpure  G2 DC Power Controller IP-POWER600-G2.

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The display board employs a 20 X 4 LCD backlit display for a clear view of data under most lighting conditions. Parameters can be adjusted and screens can be navigated using the four membrane switches on the front panel. Once the parameters have been configured, the setup menu may be locked out to require a four-digit password for further modifications. One of the two RJ-45 ports available on the back of the unit is used for connection with the G2 power controller utilizing a Cat 6 cable, Ionpure  part numbers IP-CABLE50CM-G2 or IPCABLE2M-G2. One display board can independently operate up to sixteen G2 power controllers when they are linked together in a daisy chain. No external power supply is required with the G2 display board.

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2 Installation 2.1

Requirements

The G2 Display Board meets NEMA 4/IP65 requirements when properly installed. The unit is intended to be mounted into an enclosed panel with the supplied gasket to provide a seal at the panel cutout and it is secured from the back with the provided nuts. The environmental limits for operation are 0 to 50 C at up to 95% relative humidity (non-condensing). Consider the display’s dimensions shown in Figure 2 to select the proper size for the panel.

Figure 2: G2 Display Dimensions

All connections and settings in this section should be made without energizing the power controller(s). Review other safety procedures prior to working in the panel.

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Panel Mount

To mount the G2 display into a panel: a. Prepare a cutout and four mounting holes in the door of the panel as shown in  Figure 3. All cutouts should be clean and free of burrs.

Figure 3: Panel Cutout Dimensions

b. Install the display board on the door of the enclosure using the supplied hardware and gasket.

2.3

Connections 2.3.1 Connections to a Single G2 Power Controller To connect the G2 display to a single G2 power controller: a. Connect one end of a standard Cat 6 cable to one of the two RJ45 ports on the back of the display. b. Connect the other end of the cable to one of the two RJ45 ports on the G2 power controller.

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c. Once the power controller is turned on, the display should power on. Figure 4 illustrates the connections described above:

Figure 4: Connections to a Single G2 Power Controller

2.3.2 Connections to Multiple G2 Power Controllers To connect the G2 display to multiple G2 power controllers: a. Connect one end of a standard Cat 6 cable to one of the two RJ45 ports on the back of the display. b. Connect the other end of the cable to one of the two RJ45 ports on the first G2 power controller. c. Use additional standard Cat 6 cables to daisy-chain other power controllers, as shown in Figure 5. d. Once any of the power controllers is turned on, the display should power on.

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Figure 5: Connections to Multiple G2 Power Controllers

2.4

Power Controller Setup 2.4.1 DC Output Current Range Selection To limit the possibility of applying excessive current to a CEDI module, it is recommended to select an appropriate output current range with DIP switch SW1 of the G2 Power Controller as described in Figure 6. Select the current range that can limit the current closest to the maximum value that could be required by the module. Table 3 of the G2 Power Controller manual lists the maximum DC currents required by each module.

Figure 6: Current Range Selection DIP Switch IP-POWERDSP-G2MAN Rev 2

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The G2 display will detect the selected current range upon startup and will limit the DC output current setpoint (A DC out) to this range.

2.4.2 Unit ID Selection  A unique identification number/letter needs to be assigned to each power controller that is connected to a G2 display so they can be recognized without conflicts. This is done via rotary switch SW2 of the G2 Power Controller. Each SW2 position corresponds to a channel or module (MD) identification number on the display board, as shown in Table 1. Table 1: Unit ID Selection SW2 Position

G2 Display Channel

0

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

 A

11

B

12

C

13

D

14

E

15

F

16

If two or more power controllers are mistakenly set to the same SW 2 position, the G2 display will show “ADDRESS CONFLICT” for that channel.

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3 Operation 3.1

Control/Navigation Keys

Figure 7: Control/Navigation Keys

ESC: press to exit a submenu, deactivate the cursor or discard setpoint changes. UP: press to see the previous page of information or select between submenus or configurable setpoints. When adjusting a setpoint, press to increase the value. Hold to increase the value at a higher speed. DOWN: press to see the previous page of information or select between submenus or configurable setpoints. When adjusting a setpoint, press to decrease the value. Hold to decrease the value at a higher speed. ENTER: press to activate the cursor to select submenus or configurable setpoints. Press again to enter the selected submenu or to accept setpoint changes.

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Menu Structure

Figure 8: Menu Tree Structure

OVERVIEW: this is the startup screen. It displays 3 channels at a time and shows the CEDI module’s identification number (selected on the G2 Power Controller via switch SW 2), DC output volts, DC output current and module resistance in ohms. Unused channels are represented with a line of asterisks (*). Resistance values above 999.9 are represented with “***HI”. When the DC output current is zero, r esistance will be represented with “ ----“ to indicate that resistance can not be measured. Channels 1, 2 and 3 are displayed upon startup of the unit. Pressing the UP or DOWN arrows will scroll through all 16 channels.  A blinking module number indicates where the cursor is. Pressing the ENTER key will access the RUN submenu of the CEDI module selected with the cursor.  A blinking row indicates and alarm condition for a specific power controller. The alarm type can be identified under the ALARMS submenu.

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Figure 9: OVERVIEW Screen Example

RUN: this submenu provides operational data and access to adjust the DC output current of the selected power controller, as well as access to submenus SETUP, ALARMS, LOGS and DIAGNOSTICS. There are 5 pages in this submenu. Data is grouped as follows: PAGE 1:

Figure 10: RUN Screen  – Page 1

V DC out: actual DC output voltage from the power controller to the selected CEDI module. A DC out: setpoint for the DC output current from the power controller to the selected CEDI module. Press the ENTER key to adjust this value using the UP or DOWN keys. Press ENTER again once the desired value has been set. This setpoint can not be set to a value outside the current range selected in the power controller via DIP switch SW1. Ohms pres: actual resistance in ohms of the selected CEDI module. Resistance values above 999.9 are represented with “***HI”. When the DC out put current is zero, resistance will be represented with “ ----“ to indicate that resistance can not be measured. Ohms init: initial resistance in ohms of the selected CEDI module. This value is captured when the power controller has operated continuously for 2 hours after

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48 hours of cumulative operation from the initial startup. Resistance values above 999.9 are represented as “***HI”. PAGE 2:

Figure 11: RUN Screen  – Page 2

Ohms chg%: percentage of change in CEDI module resistance from initial (Ohms init) to present (Ohms pres). Positive values represent an increase in resistance and negative values represent a decrease in resistance, in reference to the initial value. V AC in: actual AC input voltage to the selected power controller. If this value is higher than 726 VAC, a high AC input alarm will trigger. A AC in: actual AC input current drawn by the selected power controller. Power(kW): actual power consumption (Volts DC x Amps DC) in kilowatts of the selected CEDI module. PAGE 3:

Figure 12: RUN Screen  – Page 3

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Op.hours: hours in operation since the initial startup. Time is accrued only while the Remote ON/OFF input of the power controller is closed. Ic (VDC): estimated value of analog signal between terminals Ic+/Ic- of the selected power controller. Vm (VDC): estimated value of analog signal between terminals Vm+/Vm- of the selected power controller. Im (VDC): estimated value of analog signal between terminals Im+/Im- of the selected power controller. PAGE 4:

Figure 13: RUN Screen  – Page 4

Board temp: temperature in degrees Celsius of the selected power controller’s heatsink. If this value is higher than 64±4 oC, a high temperature alarm will trigger. Press ENTER to activate the cursor and use the UP or DOWN arrows to select any of the following submenus: SETUP, ALARMS or LOGS. Press ENTER again to access the selected option. PAGE 5:

Figure 14: RUN Screen  – Page 5

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DIAGNOSTICS: press ENTER to access the DIAGNOSTICS submenu.

SETUP: this submenu provides access to adjust the following settings: Ohms limit , VDC limit , Ext control , Change password? and Change module? This submenu is protected by a 4-digit password. The factory default password is 0000 and it can be changed by the user. The setting options are grouped in 2 pages: PAGE 1:

Figure 15: SETUP Screen  – Page 1

Ohms limit: the default and maximum setpoint is 996 ohms. When set correctly, this value will alert the operator of a possible issue with the CEDI module due to scaling, fouling or any other issue that could cause an abnormal increase in the resistance of the module. This value should be adjusted to match a module’s high resistance limit as follows: once the module has come to steady state (typically after about 48 hours of actual operating time), set the Ohms limit to 1.5 times the steady-state electrical resistance. This is higher than the recommendation in the EDI manual (25%) for resistance change to allow for temperature fluctuations. VDC limit: the default and maximum setpoint is 600 Volts. This voltage setting will limit the actual DC output voltage of the power controller. It is recommended that this number be set at the “Maximum Required DC Volts” value for the specific CEDI module, as described in Table 3 of the G2 Power Controller manual. If the actual DC voltage reaches the setpoint, a high DC voltage alarm will trigger. Ext control: the default setting is “No”. Changing this setting to “Yes” dis ables the DC output current control capabilities of the display board so an analog device can be used to control the DC output current of the power controller with a 0-5 VDC signal at terminals Ic+/Ic-.

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Change password?: press ENTER and use the UP/DOWN keys to change the password of the SETUP submenu. PAGE 2:

Figure 16: SETUP Screen  – Page 2

Change module?: it is recommended to use this option to reset all historic data after a module replacement. Pressing ENTER will reset the following: - Op.hours value in RUN submenu - Ohms init value in RUN submenu - Resistance alarm in ALARMS submenu - All logs in the LOGS submenu

ALARMS: this submenu displays the status of alarms and provides the option to clear them. There are 2 pages in this submenu. Data is grouped as follows: PAGE 1:

Figure 17: ALARMS Screen  – Page 1

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Clear alarms?: if any alarms are active, pressing ENTER on this page will activate the cursor to change the “N” to “Y” using the UP or DOWN arro ws. Pressing ENTER once “Y” is selected will clear all alarms that are active (not “ok”). Input VAC: reports the level status of the actual AC input voltage to the power controller. The alarm will be “ok” if the input voltage is lower than 726 VAC; it will be “hi” if it exceeds this value. Output VDC: reports the level status of the actual DC output voltage from the power controller. The alarm will be “ok” if the output voltage is lower than the value set for VDC limit in the SETUP submenu; it will be “hi” if it exceeds this value. Resistance: reports the level status of the actual resistance of the CEDI module. The alarm will be “ok” if the resistance is lower than the value set for Ohms limit in the SETUP submenu; it will be “hi” if it exceeds this value. PAGE 2:

Figure 18: ALARMS Screen  – Page 2

Board temp: reports the level status of the actual temperature of the power controller’s heatsink. The alarm will be “ok” if the temperature is lower than 64±4oC, and it will be “hi” if  it exceeds this value. Unit status: reports the status of the power controller’s power stage and temperature sensor. The alarm will be “ok” if no issues are found, and it will be “fail” otherwise.

LOGS: this submenu provides access to historical data recorded in the power controller. Data is grouped in three logs: MAX VALUES, MIN VALUES and MODULE OHMS&S. Press ENTER to activate the cursor and use the UP or DOWN arrows to select any of the data logs. Press ENTER again to access the selected log.

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Figure 19: LOGS Screen

MAX VALUES: displays maximum values of important parameters to help with performance analysis and troubleshooting. These values are monitored continuously while the DC output of the power controller is enabled (closed remote ON/OFF input).

Figure 20: MAX VALUES Screen

VAC: maximum registered AC input voltage to the selected power controller. AAC: maximum registered AC current drawn by the selected power controller. VDC: maximum registered DC output volts from the selected power controller to the CEDI module. ADC: maximum registered DC amps from the selected power controller to the CEDI module. Ohms: maximum registered CEDI module resistance, in ohms. Resistance values above 996 ohms are represented with “***HI”. Board temp: maximum registered heatsink temperature in degrees Celsius of the selected power controller.

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MIN VALUES: displays minimum values of important parameters to help with performance analysis and troubleshooting. These values are monitored continuously while the DC output of the power controller is enabled (closed remote ON/OFF input).

Figure 21: MIN VALUES Screen

VAC: minimum registered AC input voltage to the selected power controller. AAC: minimum registered AC current drawn by the selected power controller. VDC: minimum registered DC output volts from the selected power controller to the CEDI module. ADC: minimum registered DC amps from the selected power controller to the CEDI module. Ohms: minimum registered CEDI module resistance, in ohms. Resistance values above 996 ohms are represented with “***HI”. Board temp: minimum registered temperature in degrees Celsius of the selected power controller’s heatsink.

MODULE OHMS&S: this is a log of module resistance versus DC amps recorded every 24 hours. This log will contain data samples from the last 1440 hours or 60 days. The most recent data sample will be at the top of the list. The UP and DOWN arrows can be used to scroll through all the data.

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Figure 22: MODULE OHMS&S Screen

DIAGNOSTICS: this submenu provides the firmware revisions of the selected power controller, the display and the results of the power controller’s self test routine.

Figure 23: DIAGNOSTICS Screen

DCPC rev: firmware revision of the power controller. Display rev: firmware revision of the display board. Self test: a G2 power controller monitors continuously the status of its power stage and temperature sensor. The G2 display board reports in this screen the status of these components using the following codes: PASS: self test found no problems. ERR1: power stage failure. ERR2: temperature sensor failure. If the self test routine outputs error codes ERR1 or ERR2, the “Unit status” alarm will trigger. In this case, contact your Ionpure  products supplier for assistance.

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4 Getting Started 4.1

Initial Startup

The startup sequence depends on the design of the CEDI system. Please consult the Operation Manual for the CEDI system. The following startup procedure is only an example for a typical single module CEDI system: 1.

Close the main disconnect switch (or circuit breaker) for the CEDI system.

2.

Open the appropriate valves and start the pretreatment equipment, such as the reverse osmosis (RO) system, upstream of the CEDI system.

3.

Adjust the flow rates of the dilute and concentrate streams through the module.

4.

For each operating channel on the G2 display, enter the RUN submenu and adjust “A DC out” to set the DC output current to t he value calculated by the Ionpure Performance Projection Program (Current Startup Calculator). The power controller will maintain the current at that setting if the required voltage to drive the current is lower than the maximum DC voltage available.

5.

Verify that the DC output is removed when the CEDI module flow is interrupted. Operation with DC power on and insufficient water flow can cause irreparable damage to the CEDI module(s) and system.

4.2

Output Current Adjustment

The DC output current may need to be adjusted if there is a change in feed water conditions and/or flow rate.

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5 Troubleshooting Table 2: Troubleshooting Condition Display does not power on

Possible Causes Bad or incorrect Ethernet cable

Action Verify that cable is good Cable should NOT be crossover

 A channel displays asterisks

Power controller not energized

Energize power controller

Bad or incorrect Ethernet cable

Verify that cable is good Cable should NOT be crossover

Power controller in that channel is not energized

Energize power controller

SW2 position set to a different channel

See Table 1 and make sure SW2 on the power controller is set for the right channel

Display and power controller have incompatible firmware revisions

Contact parts supplier to update firmware

 A channel row is blinking

Alarm has triggered

Access ALARMS submenu to identify the alarm

 A channel displays “ADDRESS CONFLICT”

Two or more power controllers set to the same SW2 position

Set a unique ID to each power controller – See section 2.4.2

Display and power controller have incompatible firmware revisions

Contact parts supplier to update firmware

Current range set too low on DC power controller.

Select the adequate current range for the CEDI module  – See section 2.4.1

Power controller has reached maximum DC output

Verify that input voltage to power controller is adequate

Can’t adjust DC output current past a certain value

Verify that resistance of CEDI module is within specifications

VDC exceeding “VDC limit”

“VDC limit” set too low

Access SETUP submenu to adjust the “VDC limit” value – See section 3.2

Display isn’t given control

Access SETUP submenu and verify “Ext control” is set to “No”

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APPENDIX  – UL and CE Compliance

UL (US/CANADA)

The G2 display board was evaluated as an accessory of the G2 power controller. Both are recognized by UL through compliance with the following standards: 

UL 61010-1 (Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements)



CAN/CSA-C22.2 No. 61010-1 (Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements)

EUROPEAN UNION DIRECTIVE

The G2 display board was evaluated as an accessory of the G2 power controller. Both meet the Electromagnetic Compatibility (EMC) Directive 2004/108/EC and the Low Voltage Directive (LVD) 2006/95/EC through compliance with the following standards: 

EN 61000-6-4 (Generic Standards – Emission Standard for Industrial Environments)



EN 61000-6-2 (Generic Standards - Immunity for Industrial Environments)



IEC 61010-1 (Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use – Part 1: General Requirements)

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